Production Technology-I (MEPC-18)

th
B. Tech (ME) 4 Semester

Unit: 1
Milling
Prof. Hari Singh
Mech. Engg. Dept.
NIT Kurukshetra
 COURSE LEARNING OBJECTIVES
 To understand milling machine tool and associated machining operations
 To understand hole making operations
 To understand grinding process and other super finishing processes
 To understand measurement of machined surface and associated aspects
 To understand metal cutting and associated aspects
 COURSE OUTCOMES
At the end of the course student will be able to know
 milling machine tool and associated machining operations
 various hole making operations
 grinding, honing and lapping processes
 various direct and indirect methods of linear and angular measurement of machined components; types
of fits as well as gauges and its design
 orthogonal metal cutting theory, tool wear and tool life, economics and analysis of conventional
machining processes.
 INTRODUCTION
 After the class of lathes, milling machines are the most widely
used for manufacturing application. In milling, the workpiece is
fed into a rotating milling cutter, which is a multi-point tool.
The milling process is characterised by features given below.
 Interrupted cutting Each of the cutting edges removes material
for only part of the rotation of the milling cutter. As a result, the
cutting edge has time to cool before it removes material again.
Thus the milling operation is cooler compared to the turning
operation. This allows for larger material removal rates.
Fig. Schematic diagram of milling operation
 Small size of chips Though the size of the chips is small, in view of the multiple cutting edges in contact, a large
amount of material is removed and as a result the component is generally completed in a single pass only, unlike
the turning process which requires a large number of cuts for finishing.
 Variation in chip thickness This contributes to the non-steady state cyclic conditions of varying cutting forces
during the contact of the cutting edge with the chip thickness varying from zero to maximum size, or vice versa.
This cyclic variation of the force can excite any of the natural frequencies of the machine tool system and would
be harmful to the tool life and surface finish generated.
TYPES OF MILLING MACHINES

(a) Knee and Column type (b) Production (Bed) type

• Horizontal • Simplex
• Vertical • Duplex
• Universal • Triplex
• Turret type
KNEE-AND-COLUMN MILLING MACHINE
 The knee-and-column type milling machine
is the most commonly used machine in
view of its flexibility, and easier setup. The
typical machine construction is shown
schematically in figure for the horizontal
axis. The knee houses the feed mechanism
and mounts the saddle and table. The
table basically has the T slots running
along the X-axis for the purpose of work
holding. The table moves along the X-axis Fig. Horizontal knee and column type milling machine
on the saddle while the saddle moves along the Y-axis on the guideways provided on the knee. The feed
is provided either manually with a hand wheel or connected for automatic by the lead screw, which in
turn is coupled to the main spindle drive. The knee can move up and down (Z-axis) on a dovetail
provided on the column.
 The massive column at the back of the machine houses all the power train including the motor and the spindle
gearbox. The power for feeding the table lead screw is taken from the main motor through a separate feed gear box.
Sometimes it is possible that a separate feed motor is provided for the feed gearbox as well.
 While the longitudinal and transverse motions are provided with automatic motion, the raising of the knee is
generally made manually.
 The spindle is located at the top end of the column. An arbour used to mount the milling cutters is mounted in the
spindle and is provided with a support on the other end by means of an over arm with bearing to take care of the
heavy cutting forces. As shown in figure, the over arm extends from the column with a rigid design.
 The milling cutters are mounted on the arbour at any desired position.
 Milling machines are generally specified based on the following features:
 Size of the table, which specifies the actual working area on the table and relates to the maximum size of the
workpiece that can be accommodated.
 Amount of table travel, which gives the maximum axis movement that is possible.
 Horse power of the spindle, which actually specifies the power of the spindle motor used. Smaller machines may
come with 1 to 3 hp while the production machines may go from 10 to 50 hp.
  Another type of knee and-column milling machine possible is the
vertical axis type. Most of the construction is very similar to the
horizontal axis type except the spindle type and location. The spindle
is located in the vertical direction and is suitable for using the shank
mounted milling cutter, such as end mills. In view of the location of
the tool, the setting up of the workpiece and observing the machining
operation is more convenient.
 Relatively, the vertical axis milling machine is more flexible (figure)
and suitable for machining complex cavities. Also the vertical head is
provided with swivelling facility in a horizontal direction whereby the
cutter axis can be swivelled.

Fig. Vertical knee and column type milling machine

Fig. Some of the milling operations normally carried out on vertical axis machines
 BED-TYPE MILLING MACHINE
 In production milling machines, it is
desirable to increase the metal removal
rates. If it is done on conventional
machines by increasıng the depth of
cut, chatter is likely to result. However,
there is another variety of milling
machines named as the bed-type
machines, which are made more rugged
and consequently are capable of
removing more material. The
ruggedness is obtained as a
consequence of the reduction in the
versatility. The table in the case of bed-
type machines is directly mounted on
Fig. Simplex bed type milling machine
the bed and is provided with only the
longitudinal motion.
 The spindle moves along with the column to provide the cutting action. Simplex machines have only one spindle
head while the duplex machines have two spindles. The two spindles are located on either side of a heavy workpiece
and normally remove material from both sides simultaneously.

Fig. Duplex bed type milling machine

 MILLING CUTTERS
 There is a large variety of milling cutters available to suit specific requirements. The versatility of the
milling machine is contributed to a great extent by the variety of milling cutters that are available.
 Milling cutters are classified into various types based on a variety of methods.

• Solid
Based on construction
• Inserted tooth type

• Arbour mounted
Based on mounting • Shank mounted
• Nose mounted

• Right-hand rotation (counter-clockwise)

Based on rotation
• Left-hand rotation (clockwise)

• Right-hand helix
Based on helix
• Left-hand helix
 Milling cutters are generally made of high speed steel or cemented carbides.
The cemented carbide cutters can be fitted with brazed tip or more
commonly, with indexable tips. The indexable variety is more common since
it is normally less expensive to replace the worn out cutting edges than to
regrind them.
 Plain milling cutters These are also called as slab milling cutters and are
basically cylindrical with the teeth on the periphery, as shown in figure.
These are generally used for machining flat surfaces.
 Side and face milling cutters These have the cutting edges not only on the
face, like the slab milling cutters, but also on both the sides. As a result, these Fig. Slab milling cutter
cutters become more versatile since they can be used for side milling as well
as for slot milling. Staggered tooth side milling cutters are a variation where
the teeth are arranged in alternate helix pattern. This type is generally used
for milling deep slots.
 Slitting saws This is very similar to saw blade in appearance as well as
function. Most of these have teeth around the circumference while some
have side teeth as well. The thickness of these cutters is generally very small
and is used for cutting-off operation or for deep slots.

Fig. Side and face cutter

 Special form cutters There are a large number of special form milling cutters
available, which are used for machining specific profiles. Angular milling cutters are
made in single or double angle cutters for milling any angles, such as 30°, 45° or
60°. Form relieved cutters are made of various shapes such as circular, corner
rounding, convex or concave shapes.
 End mills These are shank mounted as shown in figure, and are generally used in
vertical axis milling machines. They are used for milling slots, keyways and pockets
where other type of milling cutters cannot be used. The end mills have the cutting
edge running through the length of the cutting portion as well as on the face
radially up to a certain length. The helix angle of the cutting edge promotes smooth Fig. Angle milling cutter
and efficient cutting even at high cutting speeds and feed rates. High cutting speeds
are generally recommended for this type of milling cutters.

Fig. Four flute end mill Fig. End mill used for making a slot Fig. Form relieved circular cutter
 UP AND DOWN MILLING
 Based on the directions of movement of the milling cutter and
the feeding direction of the workpiece, there are two possible
types of milling:
 Up milling (conventional milling)
 Down milling (climb milling)
 Up milling: In up milling, the cutting tool rotates in the
opposite direction to the table movement. In the conventional
or up milling, the chip starts as zero thickness and gradually
increases to the maximum size as shown in figure. This tends to
lift the workpiece from the table. There is a possibility that the
cutting tool will rub the workpiece before starting the removal.
However, this process is inherently safe. The initial rubbing of
Fig. Up milling
the cutting edge during the start of the cut in up milling tends
to dull the cutting edge and consequently lowers tool life. Also
since the cutter tends to cut and slide alternatively, the surface
generated is left with the machining marks.
 Down milling: In down milling, the cutting tool rotates in the same direction
as that of the table movement. In the climb or down milling, the chip starts
as maximum thickness and goes to zero thickness gradually an shown in
figure. This is suitable for obtaining fine finish on the workpiece. The cutting
force will act downwards and as such would keep the workpiece firmly in the
work holding device. This is good for thin and frail workpieces.
 In this case, the cutting force direction as well as the lead screw motion being
in the same direction, there is a possibility that the backlash present in the
table lead screw will interfere with the actual motion of the table by making
it jerky. Sometimes it is possible that the work may be pulled into the cutter,
which may result in a broken milling cutter or damaged workpiece, which
may sometimes be dangerous to the machine tool as well. Also, the chip
starts with maximum thickness and this gives a large force, which will have to
be taken care of by rigid lead screw for table feeding. Fig. Down milling
 In down milling, though the cut starts with a full chip thickness, the cut
gradually reduces to zero. This helps in eliminating the feed marks present in
the case of up milling and consequently better surface finish. Climb milling
also allows greater feeds per tooth and longer cutting life between regrinds
than the conventional milling.
 Advantages
1. Suited to machine thin and hard-to-hold parts since the workpiece is forced against the table or holding device by
the cutter.
2. Work need not be clamped as tightly.
3. Consistent parallelism and size may be maintained, particularly on thin parts.
4. It may be used where breakout at the edge of the workpiece could not be tolerated.
5. It requires upto 20% less power to cut by this method.
6. It may be used when cutting off stock or when milling deep, thin slots.
 Disadvantages
1. It cannot be used unless the machine has a backlash eliminator and the table jibs have been tightened.
2. It cannot be used for machining castings or hot rolled steel, since the hard outer scale will damage the cutter.
 MILLING OPERATIONS
 A large variety of components are machined on a milling machine involving various types of operations
broadly classified as
1. Plain or slab milling: It is the process which is employed for machining a flat surface, parallel to the axis of
the cutter, by using a plain or slab milling cutter.
2. Face milling: Employed for machining a flat surface which is at right angles to the axis of the rotating
cutter. The cutter used in the operation is the face milling cutter.
3. Angular milling: Used to machine flat surface at an angle other than 90° to the axis of revolving cutter.
The cutter used may be a single or double angle cutter depending upon whether a single surface is to be
machined or two mutually inclined surface simultaneously.
4. Form milling: Employed for machining those surfaces which are of irregular shapes. The cutter used,
called a form milling cutter, will have the shape of its cutting teeth conforming to the profile of the
surface to be produced.
5. Gang milling: It is the name given to a milling operation which involves the use of a combination of more than two
cutters, mounted on a common arbour, for milling a number of flat horizontal & vertical surfaces of a workpiece
simultaneously. This combination may consist of only side milling cutters or of plain and side milling cutters both.

Fig. Gang milling

 DIVIDING HEAD
 Dividing head is one of the most important attachments with
the milling machine and it is almost indispensable. The typical
construction of the dividing head is shown in figure. The main
spindle of the dividing head drives the workpiece by means of a
3-jaw universal chuck or a dog-and-live-centre similar to a lathe.

Fig. Dividing head construction

 The index plate of a dividing head consists of a number of holes with a crank and pin. The index crank drives the
spindle and the live centre through a worm gear, which generally has 40 teeth as shown in figure. As a result, a full
rotation of the workpiece is produced by 40 full revolutions of the index crank. Further indexing is made possible by
providing the index plates with equi-spaced holes around various circles. This allows for indexing the periphery of
the workpiece to any convenient number of divisions.

Fig. Indexing method of the dividing head

 The index plates available with the Brown and Sharpe milling machines are

Plate no. 1: 15, 16, 17, 18, 19, 20 holes

Plate no. 2: 21, 23, 27, 29, 31, 33 holes
Plate no. 3: 37, 39, 41, 43, 47, 49 holes

 The index plate used on Cincinnati and Parkinson dividing heads is

Plate 1: Side 1 24, 25 28, 30, 34, 37.38, 39, 41, 42 and 43 holes Fig. Index plate no. 1 of Brown
and Sharpe dividing head
Side 2 46, 47, 49, 51, 53, 57, 58, 59, 62 and 66 holes
It is also possible to get additional plates from Cincinnati to increase the indexing capability as follows.
Plate 2: Side 1 34, 46, 79, 93, 109, 123, 139, 153, 167, 181, 197 holes
Side 2 32, 44, 77, 89, 107, 121, 137, 151, 163, 179, 193 holes
Plate 3: Side 1 26, 42, 73, 87, 103, 119, 133, 149, 161, 175, 191 holes
Side 2 28, 38, 71, 83, 101, 113, 131, 143, 159, 173, 187 holes
 SIMPLE OR PLAIN INDEXING
 Plain indexing is the name given to the indexing method carried out using any of the indexing plates in
conjunction with the worm. With this method, it is possible to obtain relatively simple divisions. To
explain the procedure, let us consider that a gear is to be milled with 20 teeth. This means that the gear
blank held in the spindle of the dividing head is to be divided equally into 20 divisions. Since 40
revolutions of the index crank produces one full revolution of the workpiece, we need to rotate the index
crank two full turns for cutting each tooth of the gear.
Suppose that we want to have 6 equal divisions to be made.
40
The rotation of the index crank = = 6 23 turns
6

This means that the index crank should be rotated 6 full turns followed by two-thirds of a rotation. The
fraction of a rotation required is to be obtained with the help of the index plates as given above. This
can be done as follows using any of the Brown and Sharpe plates.
 Plate no. 1: 10 holes in 15 hole circle
12 holes in 18-hole circle
Plate no. 2: 14 holes in 21-hole circle
18 holes in 27-hole circle
22 holes in 33-hole circle
Plate no. 3: 26 holes in 39-hole circle
 Example Indexing 28 divisions
40
The rotation of the index crank = = 1 37 turns
28

This can be done as follows using any of the Brown and Sharpe plates.
One full rotation + 9 holes in 21-hole circle in plate no. 2.
One full rotation + 21 holes in 49-hole circle in plate no. 3.
 COMPOUND INDEXING
 Using the above method (simple indexing), a majority of the indexing jobs could be completed. However when
the available capacity of the index plates is not sufficient to do a given indexing job, the compound indexing
method could be used. In order to obtain more complex indexing, the following method is used. First, the crank
is moved in the usual fashion in the forward direction. Then a further motion is added or subtracted by rotating
the index plate after locking the plate with the plunger. This is termed as compound indexing.
For example, if the indexing is done by moving the crank by 5 holes
in the 20-hole circle, and then the index plate together with the
crank is indexed back by a hole with the locking plunger registering
in a 15-hole circle, as shown in figure.
5 1 11
The total indexing done is then 20− =
15 60

i.e., 11 holes in a 60-hole circle. Unfortunately the 60-hole circle is

not available in the Brown and Sharpe range of index plates.
Similarly, it is possible to have the two motions in the same
direction as well.
5 1 19
In that case, the total indexing will be 20+ =
15 60 Fig. Compound indexing using the Index plate no.
i.e., 19 holes in a 60-hole circle. It is possible, therefore, by 1 of Brown and Sharpe dividing head with 5 holes
following this method, to do any other indexing also. in 20-hole circle minus 1 hole in 15-hole circle
 ANGULAR INDEXING
 Sometimes, if it is desirable to carry out indexing using the actual angles rather than equal numbers along
the periphery, then angular indexing would be useful. The procedure remains the same as in the previous
cases, except that the angle will have to be first converted to equivalent divisions. Since the 40
revolutions of the crank equal to a full rotation of the workpiece, which means 360°, then one revolution
of the crank is equivalent to 9°
 Example Calculate the indexing for 41°.
41 5
Indexing required = =4
9 9

This is equivalent to 4 full rotations of the crank followed by 10 holes in the 18-hole circle in plate no. 1.
 DIFFERENTIAL INDEXING
 Though compound indexing is a convenient way to get any indexing
required, it is fairly cumbersome to use in practice. Hence
differential indexing is used which is exactly an automatic way to
carry out the compound indexing method. The arrangement. for
differential indexing is shown in figure.
 In differential indexing, the index plate is made free to rotate. A gear
is connected to the back end of the dividing head spindle while
another gear is mounted on a shaft, and is connected to the shaft of
the index plate through bevel gears. When the index crank is
rotated, the motion is communicated to the workpiece spindle.
Since the workpiece spindle is connected to the index plate through
the intermediate gearing as explained above, the index plate will
also start rotating. If the chosen indexing is less than required one,
then the index plate will have to be moved in the same direction as
the movement of the crank to add the additional motion. If the Fig. Dividing head setup
chosen indexing is more, then the plate should move in the opposite for differential indexing
direction to subtract the additional motion.
 The direction of the movement of the index plate depends upon the gear train employed. If an idler gear
is added between the spindle gear and the shaft gear in case of a simple gear train, then the index plate
will move in the same direction as that of the indexing crank movement. In the case of compound gear
train, an idler gear is to be used when the index plate is to move in the opposite direction.
 The change gear set available is 24, 24, 28, 32, 40, 44, 48, 56, 64, 72, 86 and 100
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